Recyclable Disposable Tableware Fabricated From Rapidly Renewable Resources

ABSTRACT

The invention provides improved tableware, comprised of plates, bowls and cups, which are formed from paperboard sheets comprised of rapidly renewable resources and are recyclable, biodegradable and compostable. The paperboard sheets are comprised of bamboo, bagasse or any combination or singularity thereof, and are coated with a polymer such as biopolyethylene, also known as renewable polyethylene, polyethylene (PE) or polylactide (PLA), and decorated with FDA approved inks and dyes, and are formed in such a manner that the resulting tableware is capable of containing a liquid without filtration or seepage upon the user.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable

BACKGROUND OF THE INVENTION I. Field of the Invention

The present invention relates to single-use tableware, More specifically, the present invention relates to recyclable, disposable tableware which is entirely biodegradable or compostable and made from specific rapidly renewable resources, those being bagasse and or bamboo, without the inclusion of previously recycled materials and utilizing only FDA approved inks and dyes for decoration.

II. Related Art

Various tableware and disposable food containers are known in the art and are commercially available. The vast majority of said products are manufactured from plastics, Styrofoam, or paper products which include wood pulp and other petroleum-based chemicals. Rapidly renewable resources such as bagasse (the dry, pulpy, fibrous matter that remains after sugarcane stalks are crushed to extract their juice) and bamboo, an extremely fast-growing grass, are not utilized in the manufacture of disposable plates and cups which are recyclable, biodegradable, compostable and maintain liquids therein.

Today, the United States Department of Agriculture, manufacturers and packagers are trying to increase the use of “biobased” products as a means to reducing North America's dependence on oil and gas from overseas sources. Products that are biobased or contain certain quantities of renewable resources does not mean these products are entirely based on renewable resources. Instead many of these products combine both naturally based materials and petroleum based materials in order to satisfy consumer needs and desires and often include a portion of recycled materials. Recycled paper products specifically, frequently contain trace levels of bisphenol A (BPA) or other chemicals used in the inks or coatings on the paper which is recycled. Thus, great care must be taken when recycled paper is used as a source material, so that unsafe levels of these chemicals are not consumed or otherwise introduced to the end user. For this reason, the present invention specifically excludes the use of recycled material in the manufacture of the tableware so as to entirely avoid this concern, as well as concerns caused by the introduction of chemicals which might be used to facilitate the removal of BPA. Additionally, the invention requires the use of FDA approved inks.

Traditional disposable tableware products, by the hundreds of millions, become fodder for the landfills that litter our continent and give rise to significant environmental concerns associated with disposal of trash.

Although these products are frequently adorned with the phrase “please recycle,” in actuality, these products are often not capable of being recycled, or cannot be easily recycled without chemical assistance, and they are not made entirely of rapidly renewable resources which are readily available as are bamboo and sugarcane, and instead contribute to global deforestation and petroleum consumption. The phase “please recycle” is then simply a hopeful suggestion to the consumer, but is often inapplicable to the product. Additionally, these products are not made from materials which are biodegradable or compostable. The forgoing invention anticipates a product which is actually and effectively recyclable, biodegradable, cornpostable, and fabricated from rapidly renewable resources without the inclusion of recycled materials or wood pulp. Biopolyethylene, a coating for such tableware, (also known as renewable polyethylene), is polyethylene made out of ethanol, which becomes ethylene after a dehydration process. It can be manufactured from various feedstocks including sugar cane, sugar beet, and wheat grain. The final product has properties which are identical to those of conventional polyethylene, is extremely versatile in terms of application and is recyclable.

In view of the foregoing, there is an absolute need for a shift towards recyclable, biodegradable, compostable disposable, cups, plates and bowls and similar tableware made from readily and rapidly renewable resources that will achieve acceptable results for the consumer, and provide a viable, green, cost effective alternative for manufacturers and consumers alike as opposed to disposable products which are wood pulp based and petroleum based and have a significant negative impact on the environment.

SUMMARY OF THE INVENTION

The present invention addresses the limitation of prior art disposable cups, bowls and similar tableware by providing a product which is manufactured from recyclable, biodegradable, compostable, rapidly renewable resources, specifically any combination of bamboo or bagasse or the singularity of either component, which grow abundantly and far more rapidly than trees. Such materials are processed in a manner which results in paperboard rolls which are coated with a polymer such as Bioethylene, also known as renewable polyethylene, polyethylene (PE) or polylactide (PLA), and then subsequently cut into the appropriate parts. These parts are then assembled into the final product utilizing a recyclable, biodegradable and compostable adhesive, such any commonly available plant-based starch or equivalents thereof which results in durable cups, plates, bowls and similar tableware which has the ability to contain a liquid for an extended duration without the liquid filtering through the structure so as to prevent unintended spillage or seepage on the end user.

The cup, which is assembled in a commonly understood process from cut pieces from paperboard sheets, specifically utilizes a rolled support ring along the top edge which aids in the stability and durability of the final product and also facilitates its use as a means to consume the liquid product inside.

In regard to bowls and plates, the paperboard rolls are cut into a circular shape and then crimped and folded along the edge or folded and adhered so as to form a raised lip which would allow a liquid to be confined within the structure and not to escape or seep onto the consumer.

In U.S. Pat. No. 2014/0097235 A1 published Apr. 10, 2014 and entitled “Bakery Boxes Having Removeable Parts comprising Plates and Other Tableware” discussed the inclusion of certain perforated shapes which can be removed from the box structure and utilized in a crude fashion as tableware, however said bakery box has the specific intention for the containment of bakery items such as a cake and the tableware which is incorporated into its structure is nothing more than flat perforated shapes which may be punched, cut, torn or otherwise removed from the box and do not have the inherent ability to contain a liquid from escaping from the confines of the tableware absent some sort of user-initiated manipulation of the edge to transform these cutouts into a vessel which might contain a liquid. Further, the box discussed in the aforementioned art, may be comprised not only of bamboo, but also of balsa or any other lightweight wood, whereas the present invention specifically excludes the inclusion of such wood products in the manufacture.

U.S. Patent No. 2014/0335236 published Nov. 13, 2014, entitled “Biodegradable, and Compostable Single-Serve Beverage Ingredient Package, anticipates a single serve cup with filtration properties that shall contain a premeasured amount of product within one chamber, separated by a second chamber, with a permeable top for use in single serve coffee and tea dispensing machines. Although it similarly seeks to be composed of rapidly renewable resources, that is where the similarities end. It is not designed to maintain liquids whatsoever and instead its intended use is as a pre-measured containment and filtration which could not be used or easily modified to function as a liquid containing bowl or cup. The addition of any type of surface coating which would prevent the loss of liquid would entirely defeat the intended use of the single serve-serve beverage ingredient package.

The forgoing summary has outlined features consistent with the present invention and in order that it may be better appreciated in its totality. The present invention is not limited in its application, details or components merely to those set forth in the descriptions and illustrations herein. The phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting unless explicitly stating as such.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing features, objects and advantages of the invention will become apparent to those skilled in the art from the following detailed description and with reference to the following drawings in which like numerals and the several views refer to corresponding parts.

FIG. 1 is a cross-section of a cup in the instant invention.

FIG. 2 is a top view of the cup “fan” superimposed upon the assembled cup in the instant invention.

FIG. 3 is a cross section view of a typical recyclable bowl or plate in the instant invention.

DETAILED DESCRIPTION

This description of the preferred embodiment is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description of this invention. In the description, relative terms such as “lower”, “upper”, “horizontal”, “vertical”, “above”, “below”, “up”, “down”, “top” and “bottom”, “under”, as well as derivatives thereof (e.g., “horizontally”, “downwardly”, “upwardly”, “underside”, etc.) should be construed to refer to the orientation as then described or as shown in the drawings under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation, Terms such as “connected”, “connecting”, “attached”, “attaching”, “joined”, and “joining” are used interchangeably and refer to one structure or surface being secured to another structure or surface or integrally fabricated in one piece unless expressly described otherwise.

As used herein, the term “corn postable” refers to a substance that (1) breaks down at essentially the same rate as commonly found paper would under similar circumstances; (2) disintegrates in the compost over time; and (3) does not produce any toxic material such that the compost cannot support plant growth.

As used herein, the term “biodegradable” means a substance or object which is capable of being decomposed by bacteria or other living organisms.

As used herein, the term “rapidly renewable resource”, refers to resources derived from plant materials which grow abundantly or more rapidly than trees, and include such plant materials as bamboo or bagasse.

As used herein, the term “recycled materials”, refers to waste products which have been treated or processed so as to make them suitable for a particular reuse, whereas “recyclable” material, as used herein, shall mean products which are capable of being treated or processed so as to make them suitable for a particular reuse.

The term “tableware” as used herein, refers to plates, cups and bowls of varying sizes and dimensions, all of which having raised sidewalls so as to have the capability of containing a liquid therein.

Recyclable, disposable, biodegradable tableware comprising paperboard sheets which are composed of rapidly renewable resources, comprising at least cups, plates and bowls are depicted in FIGS. 1, 2 and 3.

The coating for the tableware can be made of Biopolyethylene, also commonly called “renewable polyethylene, polyethylene (PE), polylactide (PLA) polylactic acid or similar polyester or other coatings derived from a rapidly renewable resource such as corn starch or sugar cane, and does not affect the recyclability of the product as these coatings can be readily stripped in the recycling process.

As shown in FIGS. 1, 2 and 3, the recyclable, disposable, biodegradable tableware is formed from a paperboard sheet comprised of rapidly renewable resources, specifically bamboo, bagasse and any combination or singularity thereof where the paperboard is coated with a polymer such as Biopolyethylene, also known as renewable polyethylene, polyethylene (PE) or polylactide (PLA), and decorated with FDA approved inks and dyes. FIGS. 1 and 2 depict a typical formation of a 16 fluid ounce cup, with a rolled lip [10] where cup is formed with an open top surrounded by the upper lip, and a continuous side wall [12] extending between the base [14] and the lip [10]. The volume and final shape of the cup may vary by alterations to the respective sizes, angles and dimensions of the comprising parts,

FIG. 3 depicts a typical formation of a recyclable, disposable, biodegradable tableware plate, fabricated from a single cut form of paperboard coated with a polymer such as Bioethylene, also known as renewable polyethylene, polyethylene (PE) or polylactide (PLA), and decorated with FDA approved inks and dyes which is then manipulated so as to cause a raised lip such that the plate, fabricated from, shall contain liquid within and prevent filtration or seepage. Again, the dimensions of the top, bottom and height are subject to variation depending on the desired final dimensions.

As should be clear from the foregoing, the use of recyclable, biodegradable, compostable materials made from specific rapidly renewable resources, those being bagasse, bamboo or any combination or singularity thereof, and coated in such a manner that liquids can be maintained therein is a key advantage of the present invention.

Assembly of the tableware is relatively straightforward and simple, utilizing starch-based adhesives which are recyclable, biodegradable and cornpostable.

To achieve a container made entirely of materials comprising recyclable, rapidly renewable resources and which are biodegradable and cornpostable, the cup and plate similarly are all made from cut forms from a paperboard roll using substances formed from fibrous plant materials which grow swiftly such as grasses like bamboo and sugar cane and specifically exclude the use of any recycled materials and wood pulp in the manufacture. Although recycled paper products are biodegradable and compostable, the use of same can introduce chemicals and BPA into the product. The resources are rapidly renewable and replenish able because they grow so quickly and are abundantly.

Many recycled paper products include trace levels of bisphenol A (BPA) or other chemicals used in the inks or coatings on the paper which is recycled. Thus, when recycled paper is used as a source material, care should be taken to encapsulate or remove such chemicals so unsafe levels are not consumed. Removal may add to cost and encapsulation may add to cost or inhibit biodegradability and compostability. These types of problems can be avoided by using virgin paper products made from plants having a short growing cycle which do not contain such harmful chemicals.

Various modifications may be made without deviating from the invention. Such modifications may concern the shapes and sizes of the various components and the materials from which the components are made. By way of example, the cup may be fabricated in a variety of dimensions so as to affect the total capacity or volume. Similarly, the plate may have an extended sidewall and increased height so that it may function as what might be commonly perceived as a bowl.

The foregoing description is intended to explain the various features and advantages, but is not intended to be limiting. The scope of the invention is defined by the following claims which are also intended to cover a reasonable range of equivalents. 

What is claimed is:
 1. Recyclable, disposable, biodegradable tableware comprising paperboard sheets which are composed of rapidly renewable resources.
 2. The recyclable, disposable, biodegradable tableware of claim 1, comprising at least cups, plates and bowls.
 3. The recyclable, disposable, biodegradable tableware of claim 2, wherein the plate is formed from a contiguous structure from a paperboard sheet with a formed raised lip.
 4. The recyclable, disposable, biodegradable tableware of claim 2, wherein the bowl is formed from a contiguous structure from a paperboard sheet with a formed raised lip.
 5. The recyclable, disposable, biodegradable tableware of claim 2, wherein the cup is formed with an open top surrounded by an upper lip, and a continuous side wall extending between the base and the lip.
 6. The recyclable, disposable, tableware of claim 2, wherein the paperboard sheet which comprises the tableware is recyclable and biodegradable or compostable, and made exclusively from specific rapidly renewable resources.
 7. The recyclable, disposable, tableware of claim 2, wherein the entirety of the paperboard structure utilized in the manufacture is composed of bagasse, bamboo or any combination thereof, and excluding any recycled materials and wood pulp.
 8. The recyclable, disposable, tableware of claim 2, wherein the paperboard sheets from which the tableware are assembled comprise one or a plurality of decorative elements utilizing only FDA approved inks and dyes which apply artistic expression to the products.
 9. The recyclable, disposable, tableware of claim 2, where the entirety is fabricated through the assembly of shapes cut from recyclable, paperboard sheet rolls as opposed to construction through wet, slurry-based processes which are subsequently heated to dry and complete the formation.
 10. The recyclable, disposable, tableware of claim 2, where the exposed surfaces of the tableware are coated with biopolyethylene, polyethylene (PE), or polylactide (PLA), such that the tableware shall contain liquids and prevent liquids from permeating or otherwise filtering through the structure. 